Interference-reducing RFID reader

ABSTRACT

An RFID reader apparatus designed to limit interference in a role of auditing individual RFID tagged or labeled items in areas of surrounding dense RIFD transponder populations. Such an RFID reader apparatus may include an RFID reader, a specialized antenna, and an enclosure, which may be constructed from ferrous material and which may be configured to hold the RFID reader and the specialized antenna in separate compartments. The enclosure may have one or more shelves, which may also be constructed from ferrous material. The RFID reader apparatus may also have a lid constructed from non-ferrous material. The RFID reader apparatus may be fitted to the bottom of an auditing workstation, for example with screws or other connectors, or may be placed within an auditing workstation specifically equipped to accommodate it.

BACKGROUND

The use of dynamic radio frequency identification (RFID) scanning tunneltechnology allows for high speed bulk reading of the RFID tags belongingto large numbers of objects. Often, such RFID tags are affixed to orintegrated into cartons that are used in a manufacturing supply chain,such that the RFID tags can be read by the scanning technology atvarious touch points throughout the supply chain. Dynamic scanningallows for a much greater efficiency than many other solutions, andoffers the capability to process much higher volumes of carton-packeditems than many other solutions.

However, one challenge with high speed scanning that must be addressedis how to deal with cartons or other items that are read by the highspeed scanning tunnel and which are flagged by the high speed tunnel asexceptions. An “exception” typically means that the carton failed insome manner; for example, a carton might be flagged as an “exception”based on the carton being short on its total expected count of items, orhaving improper items. Typically, when a carton is flagged as anexception, the carton must be opened up, and each item within the cartonmust be evaluated to ensure that the carton was properly prepared. Thismeans that, typically, the audit area of a manufacturing facility willinclude multiple stations that must be constantly attended by auditorsequipped to conduct audits of these cartons. Often, it will also meanthat items must themselves have individual RFID tags such that the itemswithin a carton can be audited within a reasonable timeframe.

Traditionally, conducting any kind of RFID audit processes in the retailsupply chain environment has been extremely challenging. The challengesto conducting a proper audit exist on several levels.

First, in a distribution center environment, there is the potential tohave a very high inventory of product, some or all of which may betagged with RFID transponders at the item level. These large populationsof RFID tags can be excited by any nearby RFID reader device emitting anRF field, which may cause inadvertent reading of tags that were notintended to be read during an audit process. For example, in some cases,even the RFID tags of items in other cartons that are moving past an RFfield can be energized, causing false reads.

Second, the methods that may be used to read tags during an audit maypose unforeseen hurdles. This may be because of, for example, theinfrequency of use of the RFID scanning technology that is used toconduct the audit, which may result in errors owing to workers'unfamiliarity with the devices, or may result in poorly-calibratedscanners escaping detection for some time. The RFID scanning devicesused for the audits may also be less sophisticated than RFID devicesincorporated into a supply chain or production line, which may result inproblems arising from the use of these “lesser designs.” This mayrequire, or may motivate, the customer or other operator of these RFIDdevices to take drastic measures in an attempt to correct the issues.

A typical RFID audit process requires the ability to perform asingulation of an RFID tag or tags. This means that, in a typical auditsolution, it is incumbent for the RFID scanning device to have a readfield that is only just large enough to interrogate a very smallpopulation of tags. This may be, for example, only around 1 to 10 tags,or may be a higher number of tags depending on the process in question.It is also extremely important that the RFID device have a verywell-defined target field in which it can read tags. For example, in onecase, the target field for an RFID scanning device may only be 12 inchessquare and emanate roughly 2 inches above the scanning surface.

Such audit processes may often make use of handheld RFID scanningdevices. While certain advantages of using handheld devices do exist—forexample, a person conducting an audit may be able to narrowly define atarget field of the desired size by utilizing a very low-ranged handhelddevice and moving it throughout the target field—this has generally metwith limited success. Likewise, in some cases, audit processes have madeuse of segregating tags to be scanned into a tightly controlledenvironment where there is no possibility that errant tags can be read;however, this is often much less convenient than the alternative, andcan be disruptive to the supply chain or manufacturing process.

SUMMARY

According to an exemplary embodiment, an RFID reader apparatus designedto limit interference in a role of auditing individual RFID tagged orlabeled items in areas of surrounding dense RIFD transponder populationsmay be shown and described. Such an interference-reducing RFID-readerapparatus may include an enclosure, the enclosure having a backplate anda plurality of sidewalls extending upwards from the perimeter of thebackplate, one of the plurality of sidewalls having a reader slot formedtherein, each of the plurality of sidewalls further comprising a flangeextending outward from the top of the sidewall, each flange having aplurality of connection sites. The enclosure may have, disposed withinit, a shelf or inner antenna tray, the inner antenna tray sized to fitwithin an enclosure cavity defined by the plurality of sidewalls, thedisposition of the inner antenna tray in the enclosure cavity defining acable slot on the plane of the inner antenna tray, the cable slotpermitting the passage of a cable from a top side of the inner antennatray to a bottom side of the inner antenna tray. Theinterference-reducing RFID-reader apparatus may further include anantenna, the antenna sized to fit within a top enclosure cavity definedby the plurality of sidewalls and the inner antenna tray and disposed onthe top side of the inner antenna tray, the antenna configured tobroadcast and receive radio-frequency signals. The interference-reducingRFID-reader apparatus may further include an RFID reader sized to fitwithin the reader slot, the RFID reader comprising a processor and amemory, the memory comprising computer code executable by the processorto cause the RFID reader to communicate with one or more RFID tags inthe field of operation of the antenna, capture data belonging to the oneor more RFID tags, and interpret the data belonging to the one or moreRFID tags, the RFID reader further comprising a data port.

In an exemplary embodiment, the interference-reducing RFID-readerapparatus may be incorporated into an auditing station. Such an auditingstation may further include a workstation platform, which may be aworking surface constructed from non-ferrous material. Theinterference-reducing RFID-reader apparatus may be located directlybelow the working surface and may be positioned such that the antenna isoriented upward.

In a further exemplary embodiment, the workstation may be used asfollows. First, a dynamic scanner may detect a carton having an abnormalnumber of RFID tags, and may divert the carton to an auditingworkstation system. A user may then remove one or more items from thecarton; scan the one or more items through the read zone of theworkstation; detect, with the RFID reader apparatus, a source of thevariant number of RFID tags, which may be, for example, a variant numberof items or an item having a variant number of RFID tags; and may repackthe carton with one or more items, which may include, for example,adding or removing items as necessary.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of embodiments of the present invention will be apparent fromthe following detailed description of the exemplary embodiments thereof,which description should be considered in conjunction with theaccompanying drawings in which like numerals indicate like elements, inwhich:

FIG. 1A is an exemplary embodiment of an interference-reducingRFID-reader device.

FIG. 1B is an exemplary embodiment of an interference-reducingRFID-reader device.

FIG. 2A is an exemplary embodiment of an enclosure.

FIG. 2B is an exemplary embodiment of an enclosure.

FIG. 2C is an exemplary embodiment of an inner antenna tray.

FIG. 2D is an exemplary embodiment of an enclosure having a lid.

FIG. 3 is an exemplary embodiment of an antenna that may be incorporatedinto an exemplary embodiment of an interference-reducing RFID-readerdevice.

FIG. 4 is an exemplary embodiment of an audit station incorporating anundermounted enclosure.

FIG. 5 is an exemplary diagram showing a flowchart of a scanningprocess.

DETAILED DESCRIPTION

Aspects of the invention are disclosed in the following description andrelated drawings directed to specific embodiments of the invention.Alternate embodiments may be devised without departing from the spiritor the scope of the invention. Additionally, well-known elements ofexemplary embodiments of the invention will not be described in detailor will be omitted so as not to obscure the relevant details of theinvention. Further, to facilitate an understanding of the descriptiondiscussion of several terms used herein follows.

As used herein, the word “exemplary” means “serving as an example,instance or illustration.” The embodiments described herein are notlimiting, but rather are exemplary only. It should be understood thatthe described embodiments are not necessarily to be construed aspreferred or advantageous over other embodiments. Moreover, the terms“embodiments of the invention”, “embodiments” or “invention” do notrequire that all embodiments of the invention include the discussedfeature, advantage or mode of operation.

Further, many embodiments are described in terms of sequences of actionsto be performed by, for example, elements of a computing device. It willbe recognized that various actions described herein can be performed byspecific circuits (e.g., application specific integrated circuits(ASICs)), by program instructions being executed by one or moreprocessors, or by a combination of both. Additionally, these sequence ofactions described herein can be considered to be embodied entirelywithin any form of computer readable storage medium having storedtherein a corresponding set of computer instructions that upon executionwould cause an associated processor to perform the functionalitydescribed herein. Thus, the various aspects of the invention may beembodied in a number of different forms, all of which have beencontemplated to be within the scope of the claimed subject matter. Inaddition, for each of the embodiments described herein, thecorresponding form of any such embodiments may be described herein as,for example, “logic configured to” perform the described action.

According to an exemplary embodiment, and referring generally to theFigures, various exemplary implementations of an interference-reducingRFID reader may be disclosed. In an exemplary embodiment, a reader and aspecialized antenna may be assembled in a custom fabricated housing. Insome embodiments, the resulting assembly may be a complete compactmodule that could be placed on top of a surface. In other exemplaryembodiments, the apparatus may be intended to be mounted to theunderside of a workbench/countertop, which may in some exemplaryembodiments be formed of non-ferrous material, to create an auditworkstation. Such a workbench may have a clean and unimpeded surfaceupon which an auditor may be able to perform tasks and engage the radiofrequency (RF) functionality of the RFID reader as needed.

Such an apparatus may allow RFID workstations to be placed side by sideone another, and may even allow RFID workstations to be placed inimmediate proximity to large RFID tag populations (such as, for example,next to a supply or production line), while ensuring that none of theextraneous tags of the large RFID tag population are read, and ensuringthat only those tags that are placed in the defined read zone of theworkstation are read.

According to an exemplary embodiment, the apparatus may include anultra-thin near-field antenna configured to broadcast a RF signal thatis in turn configured to activate and scan RFID tags. The antenna may benestled within a custom fabricated housing that projects the broadcastRF signal in a tight and controlled manner, which may limit and focusthe transmission of the RF signal.

According to another exemplary embodiment, an interference-reducing RFIDreader may be installed in or under a work surface, such as a workbench.In an exemplary embodiment, the workbench may be constructed from, ormay have a working surface that is constructed from, a non-ferrouscountertop material, which may allow the projection of an RF signaltherethrough.

Such an apparatus may have numerous advantages as compared to the use ofoff-the-shelf components, such as the use of an off-the-shelf patchantenna, in order to try to create such an audit tool. For example,according to an exemplary embodiment, an off-the-shelf patch antennacould be mounted under a table and directed upward so as to create aworking surface on a countertop above, and optionally an attempt couldbe made to try to contain the RF field. However, such a solution wouldhave numerous downsides. For example, such a patch antenna would tend togenerate side lobes of RF energy that bleed off of the edges of theantenna face, and which can even wrap around the antenna itself, such asaround the back plane of the antenna.

Patch antennas are also, generally, designed to radiate a broad RFfield, such as an RF field that is as broad as possible. This RF fieldmay be configured to balloon outward to a larger and larger size as moreand more power is forced through the patch antenna, which may decreasethe extent to which the size and shape of the RF field can besimultaneously controlled. This may heighten the chance that the patchantenna will pick up RFID tags that were not intended to be counted,resulting in inaccurate audits, or resulting in a decreased role of thepatch antenna in an auditing function (as an auditor may, for example,be forced to perform additional steps manually, such as a manual countof the items within a container).

However, when power to a patch antenna is decreased, the effectivenessof the design may be decreased. By making an effort to ensure that RFIDtags located adjacent to the patch antenna will not be accidentallyread, and decreasing the power forced through the patch antenna in orderto do so, the ability of the patch antenna to read tags that have beenplaced on the auditing bench may be reduced as well, again making itdifficult to perform the auditing process. In some cases, in an effortto make the field small enough that adjacent tags are not read, theantenna may be made less effective or virtually useless.

However, according to an exemplary embodiment, an interference-reducingRFID reader may better define the field that it projects, allowingseveral work areas each having an interference-reducing RFID readerinstalled therein to be placed side-by-side without interference withone another, and without picking up interference or noise from any otherobjects that may be expected to be nearby, such as shelves of taggedgoods that may be awaiting auditing or may have passed auditing, or asupply or production line. This may allow for an RFID audit solution tobe rolled out to environments in which high RFID inventory is presentbut the need for singulation of selected/intended RFID transponders isrequired, among other exemplary environments.

In another exemplary embodiment, an interference-reducing RFID readermay be employed in a point-of-sale role, and may be integrated into ordesigned to interface with, for example, a point-of-sale system orpoint-of-sale station. For example, in an exemplary embodiment, aninterference-reducing RFID reader may be mounted under a point-of-salestation, for example as a single apparatus (an “under-mountable RFIDsolution” or UMRS) which may improve the ability of the point-of-salestation to handle RF scanning of retail items while not inadvertentlyscanning retail items that are not intended to be scanned at the currenttime (such as, for example, retail items that have been placed on thepoint-of-sale station by other customers who are waiting to check out).

In some exemplary embodiments, an interference-reducing RFID reader maybe configured to work with a dynamic RFID system, and may be configuredto employ or facilitate dynamic scanning of application identifierswithin that system. In another exemplary embodiment, aninterference-reducing RFID reader may be used as a tool to provide oraid in any sort of RFID item scanning.

Turning now to exemplary FIG. 1A, FIG. 1A displays an exemplaryembodiment of an interference-reducing RFID-reader device 100. In anexemplary embodiment, the interference-reducing RFID-reader device 100may be provided in an enclosure 102 configured to be mounted under aworkstation or underneath another flat surface. Alternatively, in anexemplary embodiment, the interference-reducing RFID-reader device 100may be configured to fit within a workstation, such as in a hollowcavity within a workstation, if desired. Such an interference-reducingRFID-reader device 100 may include, for example, an antenna 108 and anenclosure 102 that may be sized to accommodate the antenna 108. In someexemplary embodiments, an interference-reducing RFID-reader device 100may further include a reader, which may be, for example, mounted underthe antenna 108.

According to an exemplary embodiment, such as an exemplary embodimentwherein an interference-reducing RFID-reader device 100 may beconfigured to fit under and be retrofitted to an existing auditingworkstation, the enclosure 102 may have a plurality of flanges 104,which may extend around the perimeter of the enclosure 102 around thetop of the enclosure 102. In an exemplary embodiment, flanges 104 may beflat so as to interface with a flat surface above the enclosure, such asthe bottom portion of an auditing workstation. In another exemplaryembodiment, flanges 104 may have another shape, or combination ofshapes, that may serve to interface with a surface that the enclosure102 is intended to be located below; for example, in an exemplaryembodiment, a flange 104 may have a cavity or indentation in order toaccommodate a surface geometry feature on the surface. In some exemplaryembodiments, flanges 104 may be the extensions of each of the sidewallsof the enclosure 102, and may be formed from, for example, bending thetops of each sidewall of the enclosure 102 so that the sidewall splaysoutward in the form of a flange 104. In such an exemplary embodiment,the flanges 104 may be spaced apart from one another, for example at thecorners of the enclosure 102. In other exemplary embodiments, theflanges 104 may be or may be affixed to a fused piece, for example asquare flange, which has no spacing between individual flanges 104.

In an exemplary embodiment, flanges 104 may have a plurality ofconnection sites 106 in which one or more connectors may be disposed inorder to affix the enclosure 102 to an upper surface; for example, in anexemplary embodiment, flanges 104 may have a plurality of screw or nailholes 106 disposed therein. This may allow an enclosure 102 to beattached to the underside of, for example, a wooden auditing station byinserting screws or nails through the holes 106 disposed in the flanges104.

In other exemplary embodiments, an enclosure 102 may be affixed to anupper surface, such as the lower portion of an auditing station, byanother type of connection. For example, in an exemplary embodiment,flanges 104 may be formed from, or may have attached to their uppersurface, a material offering good adhesive properties, and the enclosure102 may be adhesively attached to the upper surface. Alternatively, ifdesired, adhesive may be attached directly to the top portion of theenclosure 102, such as an enclosure lid, and no flanges 104 may benecessary. Likewise, in some embodiments, a separate retainingstructure, such as a plurality of brackets, may be used to hold theenclosure 102 to the upper surface, and no flanges 104 may be necessary.In another embodiment, the enclosure 102 may fit within a cavity in theupper surface, for example fitting within a dedicated cavity in anauditor station formed to retain an interference-reducing RFID-readerdevice 100, and again no flanges 104 may be necessary. Otherconfigurations of an enclosure, with and without flanges 104, may alsobe envisioned.

In an exemplary embodiment, the enclosure 102 may be any shape. Forexample, according to an exemplary embodiment, the enclosure 102 may besquare or rectangular. In another exemplary embodiment, the enclosure102 may be formed so as to be circular or cylindrical in shape, and mayhave a single flange 104 extending around the perimeter of the topportion of the enclosure 102, or may have a plurality of flanges 104, asdesired. Other shapes may also be contemplated.

In an exemplary embodiment, the enclosure 102 may be formed from aferrous material, such as steel, or may be formed from another materialthat absorbs RF transmissions. For example, according to an exemplaryembodiment, the enclosure 102 may be formed from sheet steel. In someexemplary embodiments, the enclosure 102 may have one or more shelveswithin the enclosure 102, which may allow the adjustment of the heightof the antenna 108 within the enclosure 102; shelves may be securable ata particular height, as desired. In some exemplary embodiments, theseshelves may be constructed from the same materials as the remainder ofthe enclosure 102 (for example, a ferrous material) and may alsofunction as RF absorbers. Alternatively, another material may be used toconstruct the one or more shelves, as desired. In some embodiments, theantenna 108 may be secured to the one or more shelves, for example bythe use of screws, an adhesive such as double-sided tape, or anothersuch connection; in other embodiments, the antenna 108 may be unsecured.

In some exemplary embodiments, the enclosure 102 may include a lid,which may be placed over the top portion of the enclosure 102. ExemplaryFIG. 1B depicts an exemplary embodiment of an interference-reducingRFID-reader device 100 having an enclosure lid 112 attached. In someexemplary embodiments, the lid 112 may be attached to flanges 104; insuch embodiments, the enclosure 102 may be attached to an upper surfaceby the lid 112 or the flanges 104, as desired. For example, in anexemplary embodiment, the lid 112 may be attached to the enclosure 102by affixing the lid 112 to the flanges 104 at the connection sites 106disposed within the flanges 104, and the lid 112 may have its ownconnection sites 114 disposed in the corners of the lid 112 by which thelid 112 may be affixed to an upper surface. In some exemplaryembodiments, the lid 112 may be constructed from a non-ferrous andnon-RF-blocking material, such as plastic. Such a lid 112 may functionto retain the components of the interference-reducing RFID-reader device100, and may protect some or all of the components of theinterference-reducing RFID-reader device 100 from potential sources ofharm, such as physical impact damage or water damage.

In some exemplary embodiments, an RFID reader 116 may be housed withinthe enclosure 102. For example, in an exemplary embodiment, a readerslot 118 may be provided, such as a space under one or more shelves,into which the reader 116 may be placed.

In an exemplary embodiment, the antenna 108 may be connected to an RFIDreader 116 by one or more cables 110. In an exemplary embodiment, theenclosure 102 may house the antenna cable 110 in order to protect theantenna cable 110 against disconnection or damage. In some exemplaryembodiments, the enclosure 102 may have a separate compartment formed toretain the antenna cable 110 and to ensure that the antenna cable 110can be easily connected to the reader 116 that may also be housed withinthe enclosure 102. In other exemplary embodiments, a main compartment ofthe enclosure 102, which may be, for example, configured to hold theantenna 108, may be slightly oversized so that there is adequate roomfor the antenna cable 110 to run between the antenna 108 and the reader116.

In some exemplary embodiments, cable connections 110 may be used forsome or all data connections between the antenna 108 and the RFID reader116, or between either the antenna 108 or the RFID reader 116 and otherhardware. In the latter case, in an exemplary embodiment, a reader slot118 may be positioned such that one or more data ports 120 of the reader116 may be exposed when the reader 116 is inserted into the reader slot.Alternatively, one or more data ports linking to the data ports 120 ofthe reader 116 may be provided in the enclosure 102 that may facilitatea connection to other hardware. A cable connection 110 may be a standardconnection, such as, for example, an RP TNC or an SMC connection, or maybe another type of connection, as may be desired. In another exemplaryembodiment, another method of data communication may be used forcommunications between the antenna 108, the RFID reader 116, and/oranother device. For example, in an exemplary embodiment, an Ethernetconnection, a wireless connection, a serial connection, or USBcommunications, or another connection or a combination of connections,may be used. A power supply cable connected to a separate power supplymay also be provided, if desired.

In an exemplary embodiment, an interference-reducing RFID-reader device100 may be constructed to function as a complete stand-alone device orsolution, rather than as a sensor intended to be operated by anotherdevice. In an exemplary embodiment, the interference-reducingRFID-reader device 100 may, for example, be configured to operate asoftware platform, and may include a processor and a memory on which thesoftware platform can operate. In an exemplary embodiment, the softwareplatform may be configured to interface with another device, such asanother device operated by an auditor at an audit workstation or anothersuch operator, and may provide feedback to the operator. Theinterference-reducing RFID-reader device 100 may also be configured tocompile and output data files using the software platform; for example,in an exemplary embodiment, the interference-reducing RFID-reader device100 may track, via the software platform, the items that the operatorhas scanned so that the results compiled by the operator can be comparedagainst other data, if desired.

Turning now to exemplary FIGS. 2A, 2B, 2C, and 2D, FIGS. 2A, 2B, 2C, and2D each show a component of an exemplary interference-reducingRFID-reader device 100.

Turning first to exemplary FIG. 2A, FIG. 2A shows an exemplaryembodiment of an enclosure 200. Here enclosure 200 may have a lowersurface 202 and one or more walls 204, which may originate from thelower surface and extend vertically or substantially vertically upward.In an exemplary embodiment, some or all of the walls 204 may terminatein flanges 206, which may extend horizontally or substantiallyhorizontally outward from the body of the enclosure 200. In someexemplary embodiments, flanges 206 may be formed from the walls 204; forexample, in an exemplary embodiment, the lower surface 202, the walls204, and the flanges 206 may be constructed from the same piece of sheetmetal, which may be bent at the interface between the lower surface 202and the walls 204 and bent again at the interface between the walls 204and the flanges 206. In some embodiments, the lower surface 202 may belarger in size than each of the walls 204, and each of the walls 204 maybe larger than each of the flanges 206; in other exemplary embodiments,each of the lower surface 202, the walls 204, and the flanges 206 mayhave different relative sizes.

In an exemplary embodiment, an enclosure 200 may have a reader slot 208disposed in the outer surface of the enclosure 200, for example in oneof the walls 204 of the enclosure 200. Such a slot 208 may allow for anRFID reader to be inserted into the enclosure 200 and accessed onceother components of the interference-reducing RFID-reader device 100 aredisposed within the enclosure 200.

In an exemplary embodiment, an enclosure 200 may have one or moremounting sites 210. In an exemplary embodiment, an RFID reader may becoupled to the enclosure 200 at the one or more mounting sites 210. Inanother exemplary embodiment, another component of theinterference-reducing RFID-reader device 100, such as a shelf componentof the interference-reducing RFID-reader device 100, may be coupled tothe enclosure 200 at the one or more mounting sites 210 by one or moreconnectors; according to an exemplary embodiment, an RFID reader may beframed inside the enclosure by said connectors, preventing the RFIDreader from shifting. In another exemplary embodiment, all three of theenclosure 200, the RFID reader, and the shelf component may be coupledtogether, such as by connectors (such as screws or bolts) that extendthrough the shelf component and the RFID reader into the mounting sites210 of the enclosure. Other linkages between the enclosure 200, the RFIDreader, and/or a shelf component may be envisioned, as desired.

Turning now to exemplary FIG. 2B, FIG. 2B displays an exemplaryembodiment of an enclosure 200 that may be formed from a single piece inits as-yet-unfolded state. In an exemplary embodiment, an enclosure 200may be formed from a single piece of sheet metal and may be bent at theinterfaces between the lower surface 202 and the walls 204, and at theinterfaces between the walls 204 and the flanges 206, to form theenclosure 200. In an exemplary embodiment, the flanges 206 of theenclosure 200 may also have a plurality of mounting holes 212 formedtherein, which may be used for, for example, mounting of the enclosure200 to the lower surface of a workstation.

Turning now to exemplary FIG. 2C, FIG. 2C displays an exemplaryembodiment of an inner antenna tray 214. In an exemplary embodiment, aninner antenna tray 214 may have a tray surface 216 and a plurality oftray supports 218, which may extend vertically or substantiallyvertically downward from a horizontal or substantially horizontal traysurface 216. In an exemplary embodiment, an inner antenna tray 214 maybe placed within an enclosure 200 such that the inner antenna tray 214can fit over an RFID reader device that may be disposed on the lowersurface 202 of the enclosure. In some exemplary embodiments, traysurface 216 may be flat; in other exemplary embodiments, one or moreportions of the tray surface 216 may be indented or formed in relief,such that an antenna with a large antenna base can lie flat on top ofthe tray surface 216 by disposing the antenna base within the portionsformed in relief. In an exemplary embodiment, the inner antenna tray 214may be formed to be slightly smaller than the enclosure 200, such thatwire may pass between the top portion of the enclosure 200 formed on topof the inner antenna tray 214 and the bottom portion of the enclosure200 formed below the inner antenna tray 214.

Turning now to exemplary FIG. 2D, FIG. 2D displays an exemplaryembodiment of an enclosure 200 having a lid 220. In an embodiment, a lid220 may be fitted to the top portion of the enclosure 200, and may fitover an inner antenna tray 214 while leaving enough room for an antennato be placed at the top portion of the inner antenna tray 214. In anexemplary embodiment, lid 220 may be constructed from a non-ferrousmaterial.

Turning now to exemplary FIG. 3, FIG. 3 displays an exemplary embodimentof an antenna 108 that may be incorporated into an exemplary embodimentof an interference-reducing RFID-reader device 100. According to anexemplary embodiment, an antenna 108 may be a near-field UHF RFIDantenna 108, having a low far-field gain; for example, in an exemplaryembodiment, an antenna 108 with a far-field gain of <−15 dB may be used.An antenna 108 may have a body 302, which may be constructed from aradio-permeable material such as KYDEX or another plastic material, andmay have a plurality of mounting sites 306, which may be spaced aroundthe perimeter 304 of the antenna 108. An antenna 108 may also have oneor more cables for data transmission 308 leading from it, which may beconnected to another part of an interference-reducing RFID-reader device100 by a standard connector, such as an SMA connector or another suchconnector, as may be desired. In an exemplary embodiment, an antenna 108may have a thin profile, and may be, for example, mere millimetersthick. In an exemplary embodiment, a center portion of the body 302 ofthe antenna 108 may be fitted with adhesive in order to better hold theantenna 108 in place in the interference-reducing RFID-reader device108. An antenna 108 may operate in a frequency range appropriate to readan RFID tag; for example, in one exemplary embodiment, an antenna 108may operate in the 902 to 928 MHz range (in order to comply with astandard set by the FCC), and in another exemplary embodiment, anantenna 108 may operate in the 865 to 867 MHz range (in order to complywith a standard set by the ETSI). Antennas 108 targeting other frequencyranges may also be understood and may be used as desired.

Turning now to exemplary FIG. 4, FIG. 4 displays an exemplary embodimentof an auditing station 400 incorporating an interference-reducingRFID-reader device 100. In an exemplary embodiment, an auditing station400 may be formed around a workstation 402, which may have a non-ferrousupper surface and open space beneath the surface in which aninterference-reducing RFID-reader device 100 may be mounted. Forexample, according to an exemplary embodiment, a workstation 402 may bea folding table having a non-ferrous countertop; alternativeorientations of workstation 402 may also be utilized or otherwiseunderstood.

In an exemplary embodiment, an interference-reducing RFID-reader device100 may be mounted to an underside surface of the workstation 402, forexample with screws, bolts, or other connectors, or another method ofmounting. For example, in an embodiment, the enclosure of theinterference-reducing RFID-reader device 100, which may be an enclosure200, may have one or more flanges 206 at the upper portion of theenclosure 200 by which the interference-reducing RFID-reader device 100can be mounted to the underside surface. For example, in an exemplaryembodiment, a plurality of screws may be disposed through the flanges206 and into the underside surface of the workstation 402.

In an exemplary embodiment, an auditing station 400 may also include apower supply 404 by which an interference-reducing RFID-reader device100 may be powered. This may be, for example, a self-contained powersupply that may allow the auditing station to be easily moved to variouspoints on a production line, or may be a connection to an external powersource, such as a wall outlet.

In an exemplary embodiment, an auditing station 400 may also include auser console 406. In an exemplary embodiment, a user console 406 mayinclude, for example, a user interface having a connection to aninterference-reducing RFID-reader device 100 and through which theinterference-reducing RFID-reader device 100 can be controlled. In anembodiment, this may be, for example, a touch-screen interface. In someembodiments, this may provide the user of the auditing workstation 400with valuable visible feedback regarding the operation of theinterference-reducing RFID-reader device 100, which may allow the userto compare what was expected to be detected by the interference-reducingRFID-reader device 100 and what was actually observed.

In another exemplary embodiment, a user console 406 may further includean RFID printer. This may allow a user of the auditing station 400 totake corrective action to generate and apply a new (i.e. corrected)label or tag to an item found to be in error, for example items withdefective tags.

A read zone 410 may be created by the interference-reducing RFID-readerdevice 100, in which items may be scanned for the presence of an RFIDtag, evaluated to determine if the correct tag has been applied or notapplied, and manually evaluated (for example, visually or physicallyinspected for accuracy of particular traits that the item should have,such as color, kind, and size) to the extent that that is necessary.

According to an exemplary embodiment, in order to use the auditingstation 400, a user may first unpack a carton by unloading the contentsonto the upper surface of the workstation 402, for example at a free endof the upper surface 408 not associated with the interference-reducingRFID-reader device 100.

The user may then slide items, item by item, across the read zone 410created by the interference-reducing RFID-reader device 100, and mayalso be manually inspected as necessary. After scanning and, if desired,manual inspection, these items may be repackaged into the carton in theevent that they are found to be correct. However, should the item befound to be incorrect, the user may be alerted by the output of the userconsole 406, and the user may be able to take corrective action directlyfocused on the specific item that was found to be incorrect beforerepacking the carton.

In an embodiment, an auditing station 400 may be paired with otherelements of a quality assurance process in order to maximize theefficiency of the quality assurance process. For example, in anexemplary embodiment, it may be undesirable for an auditor making use ofthe auditing station 400 to personally inspect every carton. In such anembodiment, the auditing station 400 may be downstream of one or moreinspection devices on a supply or production line, which may beconfigured to automatically flag suspect cartons or suspect items to beaudited at an auditing station 400.

For example, according to an exemplary embodiment, a supply chain linemay incorporate a dynamic scanning tunnel (DST) and/or a high-densityread chamber (HDRC). In an embodiment, a DST may reside on acontinuously-flowing conveyor line, such that every carton that iscarried by the conveyor line passes through the DST. The DST mayinternally project a tightly-controlled RF field, which may be used forinterrogation of said cartons. Cartons may be passed through the DST ata high speed, and the DST may perform carton reads on each carton,combining the data collected of the Carton ID with data on the totalcarton count and the itemization of each individual carton.

In another embodiment, a HDRC may be provided, which may operate insteadof or in addition to a DST. (For example, in an exemplary embodiment,cartons that have been flagged by the DST may be diverted to the HDRC.)In an embodiment, cartons may be encapsulated in the HDRC, and may besubjected to static state tests, whereby the RF signal can be set to ahigher level of regulated power, and whereby the signal will becontained on all sides instead of just by the walls of the DST.According to an exemplary embodiment, using the reflectance of thesignal on the interior surfaces of the chamber, the RF energy may bebroadcast internally to the chamber in such a manner that the RF energystrikes individual RFID inlays contained within the carton from allpossible angles. Unlike the DST, the HDRC may be used to effectivelybathe cartons in an RF field for an extended period of time, rather thanmerely passing them through an RF field for a fraction of a second. TheHDRC may thus have certain advantages over the DST in terms of accuracy;because the RF field is contained within the chamber, inventory that istagged with RFID transponders may have no bearing or impact on theevaluation of a carton being interrogated within the HDRC. The HDRC mayalso be used in circumstances where there is inventory that is adjacentto or in close proximity to the HDRC; for example, cartons may bestacked at the end of a supply line for inspection by the HDRC, and theHDRC may be used without potential interference from the stackedcartons.

In an embodiment, whether a DST, HDRC, or a combination of the two isemployed to scan a carton, upon the result of the carton scan indicatingsome mismatch, the carton may be diverted to an auditing station 400.For example, in an embodiment, a dynamic scan of a carton may indicatethat the item count of a carton is too high or too low, which mayindicate that the carton is in a shortage or over-pack situation. Oncethe scan detects that the item count is too high or too low, adownstream divert may take place, and the carton may be re-routed off ofthe supply or production line for further analysis. A user may thendetermine whether the carton has a shortage of items, whether the cartonhas the proper number of items but a shortage of RFID tags indicatingthe presence of items, whether the carton has a surplus of items, orwhether the carton has the proper number of items but a surplus of RFIDtags indicating the presence of items, and may then take steps to remedywhatever deficiency there is.

Turning now to exemplary FIG. 5, FIG. 5 displays a flowchart detailing apotential embodiment of the process outlined above. Cartons may bedynamically scanned for variance 502, such as with a DST or HDRC. When acarton with a variant number of RFID tags is detected 504, or some otheranomaly is detected with the carton, the carton may be diverted 506 toan auditing station 400. An auditor at the auditing station 400 may thenopen the carton 508, remove all items, and scan each of the items 510over an interference-reducing RFID-reader device 100 disposed under thesurface of the auditing station 400. Once the source of the problem isdiscovered, the auditor may correct the problem and repackage the carton512.

The foregoing description and accompanying figures illustrate theprinciples, preferred embodiments and modes of operation of theinvention. However, the invention should not be construed as beinglimited to the particular embodiments discussed above. Additionalvariations of the embodiments discussed above will be appreciated bythose skilled in the art (for example, features associated with certainconfigurations of the invention may instead be associated with any otherconfigurations of the invention, as desired).

Therefore, the above-described embodiments should be regarded asillustrative rather than restrictive. Accordingly, it should beappreciated that variations to those embodiments can be made by thoseskilled in the art without departing from the scope of the invention asdefined by the following claims.

What is claimed is:
 1. A method of using an RFID reader apparatus,comprising: detecting, with a dynamic scanner, a carton having a variantnumber of RFID tags; wherein the dynamic scanner comprises at least oneof a dynamic scanning tunnel (DST) and a high-density read chamber(HDRC); diverting the carton to an auditing workstation system, theauditing workstation system comprising: an RFID reader apparatus, theRFID reader apparatus comprising: an enclosure, the enclosure having abackplate and a plurality of sidewalls extending upwards from theperimeter of the backplate, one of the plurality of sidewalls having areader slot formed therein; an inner antenna tray, the inner antennatray sized to fit within an enclosure cavity defined by the plurality ofsidewalls, the disposition of the inner antenna tray in the enclosurecavity defining a cable slot on the plane of the inner antenna tray, thecable slot permitting the passage of a cable from a top side of theinner antenna tray to a bottom side of the inner antenna tray and theinner antenna tray further comprises a recessed portion adapted to holdthe antenna; an antenna, the antenna sized to fit within a top enclosurecavity defined by the plurality of sidewalls and the inner antenna trayand disposed on the top side of the inner antenna tray, the antennaconfigured to broadcast and receive radio-frequency signals; an RFIDreader sized to fit within the reader slot, the RFID reader comprising aprocessor and a memory, the memory comprising computer code executableby the processor to cause the RFID reader to communicate with one ormore RFID tags in the field of operation of the antenna, capture databelonging to the one or more RFID tags, and interpret the data belongingto the one or more RFID tags, the RFID reader further comprising a dataport; and a workstation platform, the workstation platform comprising aworking surface constructed from non-ferrous material; wherein the RFIDreader apparatus is located directly below the working surface and ispositioned such that the antenna is oriented upward; and wherein a readzone is defined on a portion of the working surface directly above theRFID reader apparatus; removing one or more items from the carton;scanning the one or more items through the read zone; detecting, withthe RFID reader apparatus, a source of variant number of RFID tags,comprising at least one of: a variant number of items or an item havinga variant number of RFID tags; and repacking the carton with one or moreitems.
 2. The method of claim 1, further comprising a lid formed from anon-ferrous material, the lid being sized to fit within an opening inthe enclosure defined by the plurality of sidewalls.
 3. The method ofclaim 1, wherein the enclosure and the inner antenna tray are eachformed from ferrous material.
 4. The method of claim 1, furthercomprising an external power supply configured to be coupled to a powersupply port disposed on the RFID reader.
 5. The method of claim 1,wherein the antenna is a near-field UHF antenna.
 6. The method of claim1, wherein each of the plurality of sidewalls of the RFID readerapparatus further comprises a flange extending outward from thesidewall, each flange having a plurality of connection sites; andwherein the RFID reader apparatus is secured to the workstation platformby connectors disposed in the plurality of connection sites.
 7. Themethod of claim 1, wherein the RFID reader apparatus further comprises alid formed from non-ferrous material, the lid being sized to snugly fitwithin an opening in the enclosure defined by the plurality ofsidewalls.
 8. The method of claim 1, wherein the auditing workstationsystem further comprises a user console, the user console comprising auser interface and an RFID printer; and wherein the step of detecting,with the RFID reader apparatus, a source of the variant number of RFIDtags further comprises displaying, on the user interface, a comparisonof an expected scan result for an item and a detected scan result forthe item.
 9. The method of claim 8, wherein the method furthercomprises: printing, from the RFID printer, a corrected RFID tag for anitem; affixing the corrected RFID tag to the item; and repacking thecarton with one or more items including the item with the corrected RFIDtag.